Structure and method of manufacturing surfaces such as tabletops

ABSTRACT

An ornamental structure is disclosing having a concretious material, an exposed design on a top surface of the concretions material, a depressed portion on the top surface, and a relief portion within the depressed portion. A method of producing the structure is also disclosed.

RELATED APPLICATION

This application is a continuation-in-part of U.S. application Ser. No. 10/806,659, filed Mar. 23, 2004, and co-owned by the inventor named herein.

BACKGROUND OF THE INVENTION

This invention relates to concrete formed structures and methods for making concrete formed structures, such as tabletops.

Many homeowners are using concrete incorporated in functional features of a home such as integral sinks, drainboards, and butcher blocks. Typically, concrete structures such as tabletops and countertops are either pre-cast in a shop or built on site. Contractors who use pre-cast concrete typically pour the concrete in the shop where conditions are controlled, using special casting structures, and they have the countertop in their possession while it is curing and until it can be adequately sealed.

Concrete structures are made of cement, lightweight aggregates, and a combination of additives. Additives such as fiber reinforcement, silica fume pozzolan, and acrylic are often used.

Some type of reinforcement is commonly used such as structural steel, wire mesh, fiberglass, and/or fibers. Sometimes more than one type of reinforcement is used.

After pouring the concretious material and adding the structural support, the concrete structures are cured. Next, countertops are ground, grinding off the surface with progressively finer diamond polishing stones. This achieves two important objectives, durability and beauty.

Next, the concrete structures are sealed. The type of seal, method and number of coats of sealer is unique to each concrete installer. Some installers prefer epoxy sealers, which are preferable harder than the concrete.

SUMMARY OF THE INVENTION

This invention relates to concrete formed structures and methods for making concrete formed structures such as tabletops. Particularly, utilizing the methods of the present invention, ornamental structures can be produced with intricate inlaid and/or engraved insignia, such as letters, designs, advertising, or other suitably attractive material. Furthermore, utilizing the methods of the present invention, ornamental structures can be produced with highly detailed features on the side surfaces of the structures, in addition to recessed or expressed relief portions.

A mold is used having an exposed top, a wall defining the exposed top, and a floor coupled to the wall. The mold further preferably includes a depressed portion mold and a relief portion mold positioned on a bottom of the mold. The mold also preferably includes a rim mold.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a mold used in the present invention, the mold bearing an insignia.

FIG. 2 is a top view of the mold, including a design and a jig.

FIG. 3 is a perspective view of a finished structure, incorporating an insignia, a design, a base, and a support.

FIG. 4 is a perspective view of the structure of the present invention, the structure bearing an insignia, a design, a depressed portion, and a relief portion.

FIG. 5 is a cross sectional view of the present invention shown in FIG. 4.

FIG. 6 is a cross sectional view of a second embodiment of a mold used to form the structure of the present invention shown in FIG. 4.

FIG. 7 is a perspective view of the structure of the present invention shown in FIG. 4, including a base and a support.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.

Referring now to FIG. 1, a perspective view of a mold 10 used to produce a tabletop or other structure 60 (shown on FIG. 3) in the present invention is shown, the mold 10 bearing an insignia 30 on an inside wall 20 of the mold 10. The insignia 30 is a mirror image of the desired end product insignia, because the insignia 30 will then be legible outside the mold 10. It is noted that the insignia 30 is preferably positively formed (i.e., not an indentation in the mold 10) in order that the insignia in the structure 60 will ultimately appear engraved. However, it is understood that the insignia 30 could also be an indentation in the mold 10, to produce a positive emblem on the structure 60.

Because the insignia 30 can be as detailed as a user desires, it is preferable that a relatively soft molded rubbery material is used to form the mold 10 to both ease eventual withdrawal of the mold 10, yet provide enough rigidity to sustain the detail level of the insignia during curing.

One preferred material for the mold 10 that the inventor has found advantageous is a liquid mold rubber composition, such as polyurethane RTV (or “Room Temperature Vulcanizing”) mold rubber, manufactured by PolyTek Development Corporation of Easton, Pa., who provide flexible high strength rubber for making tough durable molds.

Referring now to FIG. 2, a top view of the mold 10, including a design 40 and a jig 50 is shown.

As can be seen in FIGS. 2 and 3, to manufacture a structure 60, first the mold 10 is provided. Next, the manufacturer places a design 40, if desired, into the bottom 12 of the mold 10, the bottom 12 filled portion of the mold 10 ultimately becoming the top 62 of the structure 60.

A lightning bolt is shown as a design 40, although the shape, size, color, and composition of the design 40 can vary widely in accordance with user preference. For instance, any type of design, such as a trademark for marketing purposes, can be employed as a design 40, creating an effective marketing tool.

Preferred materials to create the design 40 include, but are not limited to, acrylic, stainless steel, aluminum, brass or the like.

A weighted jig 50 is placed on top of the design 40, such that the design 40 remains on the bottom 12 of the mold 10 when the concretious material 14 is poured into the mold 10. The shape of the jig 50 may vary from that shown. The jig 50 is provided so that the concretious material 14 does not travel under the design 40, so that the design 40 remains apparent to viewers after the mold 10 has been removed (described later).

Next, the manufacturer fills the mold 10 (not shown) with suitable concretious material 14, such as cement, lightweight aggregates, and/or any combination of additives, as fiber reinforcement, silica fume pozzolan, acrylic, coloring materials in accordance with manufacturer preference.

Next, the manufacturer preferably gently vibrates the filled mold 10 (not shown), allowing air bubbles to escape the concretious material 14 contained in the mold 10.

Next, the manufacturer strikes off, or levels, extra concrete material 14 from the top of the mold 10 (not shown), creating a relatively even surface that will eventually become the bottom of the structure.

Additionally, the manufacturer can place reinforcement, such as steel, within the concretious material 14 (not shown).

Next, the manufacturer again trowels or strikes off, or levels, extra concrete material 14 from the top of the mold 10 (not shown), creating a relatively even surface that will eventually become the bottom of the structure.

Next, the manufacturer inserts a suitable base 70 (shown on FIG. 3), into the top of the concretious material (that will eventually become the bottom of the structure). The base 70 can vary widely, but one preferable base is a metal structure that is coupled to the concrete material 14 by an anchor/bolt system (not shown) coupled to the base 70 and the concretious material 14. Also preferably, the base 70 will have a threaded coupler (not shown) for coupling a remaining base support, such as support 80 shown on FIG. 3.

Next, the manufacturer allows the concretious material 14 to cure, preferably overnight. At this point, the concrete material 14 has dried from a wet condition to a “green” condition. At this point, the manufacture can remove the mold 10 from the structure 60.

The structure 60 is then allowed to “rack” or dry for preferably a period of two days, dependent on the type of concrete material 14 employed.

At this point in the process, the structure 60 is in a dry condition. Preferably, a slurry is used to fill in any void space that the manufacturer wishes to cover (not shown), and again the structure 60 is allowed to sit to allow the slurry to dry.

Preferably, the structure 60 is then polished, such as with a circular sanding device, to remove any of the concretions material that may have concealed portions of the design 40.

Next, a coating is applied to the structure 60, and any excess coating is then removed if desired.

As shown in FIG. 3, a finished structure 60 is then produced, with an insignia 30, a design 40, a base 70 and a support structure 80.

FIGS. 4 and 5 illustrate another embodiment of the structure 60. The structure 60 preferably comprises one or more designs 40, a depressed portion 42, and a relief portion 44 within the depressed portion 42.

Referring to FIG. 5, it may be seen that the structure 60 preferably includes a lip or rim 90 within the depressed portion 42. The rim 90 is adapted to provide support for a removably seated glass cover 92, although other materials may be used for the cover 92, such as plexiglass or the like. The cover 92 is preferably placed over the depressed portion 42 and the relief portion 44 and is supported by the rim 90. Alternatively, the cover 92 may be sized to cover the entire top 62 of the structure 60, or any portion thereof. It is also within the scope of the invention to have no cover 92 at all.

Referring now to FIG. 6, a mold 100 is shown having an exposed top 102, a wall 104 defining the exposed top 102, and a floor 106 coupled to the wall 102. The mold 100 further preferably includes a depressed portion mold 42′ and a relief portion mold 44′ positioned on the bottom 112 of the mold 100. The mold 100 also preferably includes a rim mold 90′.

In a preferred alternative step to the use of the jig 50, a spray adhesive is applied to the bottom surface 112 of the mold 100. Next, the design 40 is adhered to the mold 100 by the adhesive. In this way, the adhesive can either supplant or supplement the necessity for the jig 50, decreasing costs and the number of materials required.

Referring now to FIG. 7, a perspective view of a finished structure 60, incorporating an insignia 30, a design 40, a depressed portion 42, a relief portion 44, a cover 92, a base 70, and a support 80 is shown.

The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. 

1. A method of making a concrete structure comprising: providing a mold with a bottom surface and an exposed top, a depressed portion mold positioned on the bottom surface, and a relief portion mold positioned within the depressed portion mold; placing a design on the bottom surface of the mold; filling the mold with a concretious material; allowing the concretious material to dry for an initial drying period; and removing the mold from the dried matrix.
 2. A method according to claim 1, the method further comprising: including one of providing a weight atop the design and applying an adhesive to the bottom surface of the mold prior to the step of placing a design on the bottom surface of the mold.
 3. A method according to claim 1, the method further comprising: applying an adhesive to the bottom surface of the mold prior to the step of placing a design on the bottom surface of the mold; and providing a weight atop the design.
 4. A method according to claim 1, the method further comprising creating an insignia in a sidewall surface of the mold prior to filling said mold.
 5. A method according to claim 4, wherein the insignia is a negative impression of a desired insignia.
 6. A method according to claim 4, wherein the insignia is a positive impression of a desired insignia.
 7. A method according to claim 1, the method further comprising vibrating said mold prior to allowing the matrix to dry.
 8. A method according to claim 1, the method further comprising leveling excess concrete to even with the exposed top prior to allowing the matrix to dry.
 9. A method according to claim 1, the method further comprising providing reinforcing steel into the concrete matrix prior to allowing the matrix to dry.
 10. A method according to claim 1, the method further comprising coupling a base structure to the concretions material prior to allowing the concretious material to dry.
 11. A method according to claim 10, the method further comprising coupling a support structure to said base structure.
 12. A method according to claim 1, the method further comprising allowing an additional drying period following removing the mold from the dried concretious material.
 13. A method according to claim 14, the method further comprising grinding a top surface of the structure following allowing an additional drying period, thereby exposing the design on the structure.
 14. A method according to claim 1, the method further comprising applying a slurry to a surface of the structure, thereby filling undesired void spaces.
 15. A method according to claim 14, the method further comprising allowing a second additional drying period following the slurrying step.
 16. A method according to claim 1, the method further comprising polishing the structure to a desired finish following said initial drying period.
 17. A method according to claim 1, the method further comprising applying a finishing coat of a desired sealant to said structure following said initial drying period.
 18. A structure formed by the method of claim
 1. 19. A structure comprising a concretious material, an exposed design on a top surface of the concretious material, a depressed portion within the top surface, and a relief portion within the depressed portion.
 20. A structure according to claim 19 further comprising an insignia on a side surface of the structure.
 21. A structure according to claim 19 further comprising a rim positioned within the depressed portion, whereby a cover is removably seated on the rim.
 22. A mold for a structure comprising: a wall; a floor coupled to the wall, the floor having a bottom surface; a depressed portion mold positioned on the floor of the mold; and a relief portion mold positioned within the depressed portion mold.
 23. A mold according to claim 22, further comprising a rim mold positioned within the depressed portion mold. 